Fluid fuel control means



0d. 6, 1936. 1 WHALEN 2,056,414"

FLUID FUEL CONTROL MEANS Fil'ed June 21, 1934 s Sheets-Sheet 1 INVENTOR JAMES WHALEN,

ATTORNEY J. WHALEN Oct. 6, 1936.

FLUID FUEL CONTROL MEANS 3 Sheets-Sheet 2 Filed June 21, 1934 7 mm m INVENTOR 11 IIILIL W ,IIII/III/llI/IIIIIIIIIIII ATTORNEY JAME WHALEN.

Oct. 6, 1936, J. WHALEN 2,056,414

FLUID FUEL CONTROL MEANS Filed June 21, 1934 3 Sheets-Sheet 3 INVENTOR- -1JAMES WHALEN.

C 7 ATTORNEY Patented Oct. 6, 1936 UNITED STATES PATENT OFFICE 4 Claims.

This invention has to do with means for controlling fluidfuel and particularly to modulating valves employed for regulating the supply of fluid fuel to furnaces or the like.

In its preferred embodiment the invention is for use in connection with furnaces using fluid fuel such as gas or oil and said device is used in combination with an electric thermostat for controlling the operation thereof. It comprises a valve, automatic valve operating means, adjustable modulating means, means for manually operating the valve upon the failure of the electric current supply, damper and draft operating means, and fan controlling means for a fan for forcing air through the heat conduits of the furnace.

While the invention includes the combined instrumentalities above mentioned, I wish it to be understood that I consider the aforesaid valve and means not only combinatively novel, but in so far as I am advised, certain of the devices going to make up such valve and means are new in less combinations than the whole, and some capable of individual use, as will more clearly appear hereinafter.

To fully explain the advantages of my invention I shall refer briefly to the operation of wellknown types of fluid fuel valves for furnaces which have electric thermostatic means for con trolling the operation thereof. In these valves there are substantially but two positions, the closed position and the open position. The thermostat situated in one of the rooms of the house and set for the desired house temperature. When the house temperature falls low enough, usually several degrees below the temperature for which the thermostat is set, the thermostat closes an. electric circuit to the valve operating mechanism which operates to open the valve. The fuel thereupon passes on to the burner which burns with a full flame. The furnace then heats the house until the temperature rises to a predetermined point, as fixed by the thermostatic setting, which point usually being several degrees above the temperature for which the thermostat is set. At this point the thermostat, which has already opened the above. mentioned circuit, closes another circuit which causes the operating mechanism to close the valve and shut off the fuel to the burner. The furnace now ceases to heat the house until the temperature in the house drops to a point that will cause the thermostat to start the burner again. During this period between the shutting off of the furnace and the starting up again thereof no heat is developed. for delivery to the rooms of the house and as a consequence a layer of cold air forms on the floors of said house.

With the foregoing in view it'is my object to provide fluid fuel control means especially adapted for use with furnaces, and operable to start and shut off the supply of fuel or to allow a limited amount of fuel to pass therethrough to the furnace burner to operate said burner at a reduced or modulated heating speed to supply heat to the house at all required times.

Another object is to provide means for adjusting the amount of fuel passing to the burner when said burner is operating: at the reduced or modulated heating speed.

A further object is to provide an electric-motor-driven valve actuating means having special thermostatically controlled relays for controlling the electric circuits of the valve actuating means.

Further objects are to provide means for man ually operating the valve in case of failure of the electric current and means for releasably securing the valve in the open position;- to provide means for actuating dampers and drafts to supply more or less air respectively as the valve opens or closes in controlling the fuel supply to the burner for more or less heat; and to provide an electric switch and switch actuating means for controlling the electric circuit to an electric fan for forcing air through the furnace heating conduits when the furnace is operating at the reduced or modulated heating position.

Other objects of the invention will appear in the following detailed description taken in connection with the accompanying drawings wherein:

Figure 1 is a longitudinal vertical section on line I'-l of Figure 3.

Figure 2 is a rear View of the valve actuating mechanism with the'cover cut away and showing the lever for manually operating the valve, said lever also providing means at each end for actuating dampers and drafts.

Figure 3 is a front view of the valve actuating mechanism with the cover partly broken away.

Figure 4 is a side view of the adjustable modulating means in the valve-closed position.

Figure 5 is a front View of the modulating means with. the dial removed and with the shaft and sleeve of the said means cutoff in a plane with the said. dial.

Figure 6 is a plan view of the modulating pawl and fan switchand the means for operating said switch.

Figure '7 is a front view of the modulating means including the valve and valve cup.

Figure 8 is a diagrammatic view of the electric circuits of the invention.

Referring more particularly to the drawings reference numeral IIJ indicates a base upon which vertical frame members II and I2 are secured to said base by screws I3 through angled portions I4. The upper ends of the frame members I! and I2 are held in spaced relationship with each other by separating posts I4a secured between said frame members by suitable screws 26. An electric motor I5 is supported adjacent to the outer side of the frame member I I on posts I6. The motor shaft I'l passes through an opening provided therefor in the frame member I I, said shaft having a gear I8 secured on the end thereof. Power is transmitted from the motor through said gear I8 to a shaft I9 mounted in the upper part of the frame members II and I2 by means of a chain of gears respectively numbered 20, 2I, 22, 23, and 24 from the motor gear I8 and operatively mounted between the frame members H and I2. The above gears are adapted to reduce the speed of rotation of shaft I9 relative to the speed of rotation of the motor shaft IT. The rear end I9a of shaft I9 extends through frame member I I and projects outwardly thereof within a spring housing 25 secured to the outer side of the frame member II by means of screw 26. A coil spring 21 is provided within the housing 25 for rotating the shaft I9 in one direction, said spring having one end suitably secured to the housing and the other end secured to the shaft I9 by a pin 21a.

A valve actuating eccentric 28 is secured .to shaft l9 between the frame members II and I2 behind the gear 24. A collar 29 is received in a groove formed in the eccentric by a flange 30 on one side and a washer 3I on the opposite side thereof. A connecting member 32 connects the collar 29 with a plunger 33 slidably received in a bearing 34 secured in an opening provided therefor through the base ID. The connecting member forms an integral part of the collar 29 but is pivoted in a slot 35 in the upper end of the plunger, a screw 35a being the pivot upon which the connecting member swings.

A cylindrical depending member 35 is secured to the under side of the base I0 by screws through said base or other suitable means, said depending member forming a casing around the lower end of the plunger. A soft flexible diaphragm 31 is secured to the lower edge of the depending member 35 by means of a washer 38 pressed tightly against the under side of the diaphragm and adjacent the outer edge thereof, said washer being secured to the depending member by screws 39 threadably received in openings provided therefor in the depending member.

A valve housing 40 is threadably secured to the depending member 36 by a coupling 4I operatively abutting on an outwardly extending flange 42 on the depending member 36 and adjacent the lower edge thereof. A gas tight union is made by providing a gasket 43 between the washer 38 and the upper edge of the valve housing 40. The upper portion of the valve housing 40 is provided with an enlarged chamber 44 within which the diaphragm may freely operate. Below the chamber 44 and communicating therewith is a vertical cup chamber 45 within which a cup 46 is secured by a removable ring or valve seat 41, said ring being received in an opening in the bottom of the cup provided therefor. Said ring also being threadably received in an opening in the bottom of the cup chamber. An outwardly extending flange 48 of the ring engages the bottom 49 of the cup to draw said cup tightly against the bottom of the cup chamber. Cups having different sized gas openings may be used by removing the ring and cup and inserting a cup with the desired sized openings. The new cup is secured in the cup chamber by tightly replacing the ring.

A cylindrical piston-like valve plunger 50 is operatively received within the cup 46. The valve plunger is securely connected to the plunger 33 by a valve stem 5|, the upper end of said stem being threaded and screwed into a threaded opening in the lower end of the plunger 33, the upper end of said stem passing through an opening in the diaphragm 31. A washer 52, immediately below the diaphragm, is snugly held against said diaphragm by a nut 53 on the valve stem to seal the diaphragm around the valve stem. The lower end of the valve stem is provided with a downwardly extending portion 54 of a diameter smaller than the diameter of the stem and thereby forming a shoulder 55 against which the upper surface of the valve plunger abuts, the valve plunger being provided with a downwardly extending hublike portion 56 having a central opening therein to receive the extension 54 of the valve stem. A nut 51 on the end of said extension secures the valve plunger 50 to the stem, the end of said extension and nut being covered with a cap 58 threadably received on the hub 56. Said cap also serves to secure a washer 59 on the lower surface of the valve plunger 50. A downwardly extending skirt 60 forms a wall which protects the outer edge of the washer 59 and lengthens said valve longitudinally. The washer, when the valve is in the closed position, rests on the upper edge of the ring 41 to prevent the passage of gas from the inlet chamber 6| of the housing 40 into the cup. The valve plunger is also provided with upwardly extending skirt 62 to give additional length thereto, said valve plunger 50 being of such length as to cover, when in the closed position gas passages 53, 64, 65, and 66 through the wall of the cup. The flow of gas is indicated by the arrows 6! and 68. The gas enters the housing through the inlet 69, passes into the inlet chamber SI and from chamber 6| through the central opening ID in the ring 41. one of the four modulating positions, indicated by the dotted lines numbered I, 2, 3, and 4 in Figure 7, the gas passes through said central opening I0 into the cup and thence through opening 63 in the cup wall and thence into the outlet chamber II of the housing 40. From the chamber II the gas is conducted by suitable pipes to the furnace burner. The inlet and outlet sides of the housing are separated below the cup chamber by a vertical partition Ha.

The valve is opened by the operation of the electric motor I5 actuating the gears I 8, 23, 2!, 22, 23, and 24 causing shaft IS to rotate. As the shaft rotates the eccentric is also rotated and said eccentric imparts a reciprocating movement to the connecting rod 3 thus drawing the plunger upwardly and thercby drawing the valve plunger 5c upwardly to expose the openings 63, 84, E5, and 56 in the cup to permit the flow of gas therethrough.

To maintain the valve in its open position the motor i5 is stalled with the electric current passing through the motor coils. Upon the shutting off of the electric current to the motor the spring 2?, which is wound upon the rotation of the shaft With the valve in any it. by themotor, actuates-the shaft l9-iin theopposite direction thereby. closing said:' valve; the eccentric beingon lower dead center-:- or: substantially. so' when the valve plunger. is' in; the closed position .holdssaid valve plunger against any upe ward movement due to pressure;- a-gainst therbottom thereof.

The modulating.mechanismcomprises: a disk 12 securedby. a pin l3;to,the shaftTIQ", said..disk'supporting a dial 14. in spacedassociation"therewith upon posts 15 secured between said disk I2 and dial-'iiby screws H5. The dial Mas provided with a-nqopen-ingthroughwhich the shaft 19 extends forwardly. thereof 3 and said opening is large enough to accommodateslidablya sleeve 'H carried on an adjustment disk-18: and extending forwardlyof saidadjustment disk. Theadjustment diskl'lltmay be slidably and rotatably moved on the shaft i 9 but is normallylocked inengagement with disk lit-by means hereinafter described. The

rears-ideof said adjustment disk is=-norma1ly in contacttwith the front side of disk 12 and receives the hub i ofi said: disk 12 in arecess adapted therefor. Said" disk i8- is urged against disk 12 by a spring-fle within av recess at in the sleeve T! andaround the'shaftiii. The rear.- end: of the spring 89.,abuts-iagainst a shoulder 82 and the front end thereof abuts against a washer 83 securedtc the forward end .of shaft l9 by a screw 81min said'shaft. The forward endofv sleeve Ti is received withinan elongated knob 1 85., secured thereto by-a set screw 86. The knob 85 is-provided at its rear endlw-ith an-indicator arrow B? for indicatingthe various modulating positions of the valve, saidadjustments being. made by pulling the knob forwardly until the pins 88 of the adjustmentdisk '18 are completely withdrawn from their-respective holes in the disk E2 and turned for insertion into other holes in-the disk 72.. The disk. 12 isprovided with two series-of four holes diametrically opposed and are adapted to provide four adjustmentpositions forthe. adjustment disk. A notch-86 in one side of disk l3-slidably receives a pin Meet in disk l2-and saidv notch s adapted to provide shoulders 9i for limiting .the rotary movement of the disk 73' relative to disk '82.. Thedisk 18 is provided with anarm' 92 extending radially therefrom' and having adjacent the outer end thereof a forwardly ext-ending roller 93' rotatably mounted on, a screw 94; said screw being screwed into a suitableopening in the arm S2. During the opening of the valve. the" arm moves in a clock-wise direction from a substantially horizontal position to the rig-ht of the shaft 59 to a substantially horizontalipcsition opposite thereof. Said arm moves withrthe shaft ilfand is held against rotary movement'relatives thereto by the locking togetherof the disk 78 and the disk 12'. During the closing of the valivethe arm 92 moves in the same path as taken during-thenpene ing thereof but in the opposite direction; The return movement of the arm may be interrupted by a pawl 95 operatively hinged to a support 96 by a screw 91', said support being secured to the frame member l2 and spaced forwardly thereof by collars 98; screws 99Jsecuringsaid :support to the'frame member !2.

Thepawl 95is provided with-a notch lfift inits free swinging end adapted, when the pawl is in the uppermost position, to engage the. roller 93 of the arm 92 to limit the return movement there of, thereby interruptingrtheclosing of the valve at a point intermediate of the fully opened and the closed position. The valve in vsaidinterinediate or modulate-position exposes portions i of hole $3tin1 the cup M6 topermit? a: limited: supply of 'fuel' to pass-wtlierethrough. The amount of fuel permittedtopass throughsthe opening 63 in the'oupis determined by the respectiveposition ofi'the valve plunger 50 as adjusted by the adjustment ofi theedisk: ltzrelative to the disk l2, said adjustmentsci the disks wand EZIdeterminingrandLlimiting the downward movement of the valve-plunger 59.. The fourradjustment positions are indicated onthe-dial 'M'by; the numerals l, 2;, 3;.and'13 'and3the respective valve positionsrclative: to. tl'ie'opening. 6'3: are indicated: by the dottedislinesa I; 2;..3;.and 4 in Figure 7;

In:.the;heating ofazhouse'aethermostat H31 is secured: in. theusual way: in one-of the rooms of said; house. As. the house temperature drops, the arm 32 of the thermostat contacts point C thereof:- closing. the electric. motor. circuit and operating'themotor [Sr-which in turn operat s the valve opening means to fully open the valve at which position. the-:motonstalls and maintains thevalve in'said-open position as long as the arm lil2cof the thermostatcontactspoint C and maintains the electric circuit to the'motor.

With one. exception to be hereinafter-noted, the circuituto-relay M33 is alwaysaclosed during the operation and use of'the valve. As the circuit is closed-a soft-iron core I04 is energized to draw an-arm 35 against said core. Apin. E88, extend:- inglaterally from the arm and received betweena-downwardlyextendingarm in! of he pawl 95 and a downwardly extending spring we, moves said spring forwardly thus raising tl efree endof the pawl upwardly into the position shown in'Figure '7 inwhich position the pawl isadapted to engage-the roller 93 of the arm stand limit the: return movement of said arm. The'return movement of the arm occurs when the house'temperature. rises and-the arm 2920f the thermostat moves away from'point C breakingithe circuit to the motor.

Tl'le motor'then ceases to maintain the valve in the open position and allows the spring 21 to rotatethe shaft lfiqin a counter-clockwise direction; The movement of said shaft is interrupted by the engagement of the roller 93 of arm 92 with the end of the-"pawl 95. The valve, remaining in-a partly open position, permits a limited amountof fuel to. pass-through the opening 63 in thescup lt, said fuel passes on to the burner which'continues to burn and heat the house at areduced heating. speed until the temperature may-againdrop low enough to cause the arm I62 of the thermostat to contact point C and start the electric motor again to fully open the valve. Dues-to the-operation of the burner at a reduced heating speed;.the house temperature will drop very slowly'and saidconstant operation of the burner will provide an uninterrupted supply of heat to the rooms of the house at all required times" thus preventing the formation of a layer of. coldair on the floors of the house. As the roller 93 engages the free swinging end of the pawl 95 contact .is made with the projecting end HIS-of arod lit, slidablyreceived. in a longitudinal-openinginthe pawl, and said rod is forced inwardly. The rear end lll-of'the rod extends transversely of the pawl and is operatively connectedto an arm.ll2 extending rearwardly of a springswitcharm H3. As the rod Iii] moves-- rearwardlythe switch arm is moved. toward a switch arm lM'until contact is made between contact points I 15 and. H6'of switch arms 5 I3 and H4 respectively. The contact between the contactzpoints. l 1 Sand I IG isadapted to close an electric circuit to an electric motor-driven fan for forcing air through the heat conduits of the furnace when said furnace is operating at the modulated burner speed. The fan is only needed to force heat through the conduits while the furnace is operating at the modulated burner speed as only a relatively small amount of heat is then developed by the furnace. With the valve in its fully open position the roller of arm 92 is out of contact with the rod H0 permitting the tension of the spring switch arm I I3 to break the contact of contact point I I5 with contact point I I6 thereby shutting off the fan. The natural tendency of heated air to rise will carry said heated air up through the heat conduits of the furnace to the various rooms of the house when the burner is operating at full flame.

As the circuit to the relay I03 is normally closed at all such times as the furnace is being operated the pawl 95 is in the upper position. Should the valve be closed with the pawl in said upper position said pawl may be depressed by the roller 93 as it travels from the closed to the open position of the valve due to the yielding qualities of the spring I08. The spring I08 will raise the pawl to the upper position again upon the passing of the roller past the end of the pawl.

Should the outside temperature rise unseasonably or otherwise so that the house will become unduly warm the thermostat arm I02 will move into contact with point H thereby closing the electric circuit to relay H1. The iron core of said relay will thereupon become energized and will draw lever II8 thereagainst. As the lever H8 is drawn against the iron core of said relay II'l the circuit to relay I 03 is broken by the raising of a contact bar I I9 from a pair of spaced contact points I 20, said contact points being insulated from each other. Upon the breaking of the circuit to relay i 33 a pin I2I slidably mounted in an opening I22 in the core of said relay is urged outwardly by a spring mounted in said opening I22 behind said pin I2I. The outward movement of the pin IZi forces the lever I05 away from the relay core thus forcing lever I01 of the pawl rearwardly and thereby drawing the free swinging end of the pawl downwardly and rel asing the arm 92 of the adjustment disk I8. The spring 27 thereupon operates to completely close the valve and shutting off the burner of the furnace until the temperature of the house drops enough to cause arm I02 of the thermostat to come into contact with point C thereof and opening the valve to start the burner operating with a full flame.

However, as soon as the temperature drops enough to cause arm I92 to break contact with point H of the thermostat the circuit to relay I I1 is broken and a pin I22 slidably mounted in an opening I23 in the core of relay H! is forced outwardly by a spring I24 operatively mounted within the opening I23. The outward movement of the pin I22 forces lever I I8 outwardly from the core and brings contact bar II 9 into contact with contact points I20 thereby closing the circuit to relay I03 which operates to raise pawl 95 to the upper position in which position it is again ready to interrupt the arm 92 and hold said arm in the modulating position. All electrical circuits are suitably insulated and the contact bar H9 is suitably insulated from electrical contact with lever II8 by pieces of insulating material I lfia secured to said lever I I8 by a screw I25.

In case of electric current failure the valve may be operated manually by a double arm I 26 pivotally mounted to frame member I2 by a screw I21. Centrally positioned on the upper side of said arm and with the screw I27 as an axis is a gear segment I28 operatively meshed with a pinion I29 secured to shaft I9 between the outer side of frame member I2 and disk 12. The valve is opened manually by moving the arm I21 from the position shown in dotted lines in Figure 2 to the position shown in solid lines in the same figure.

A pawl I30 is provided to releasably lock the arm I25 in the open position. The pawl is secured to a pin I3I having the ends thereof pivotally mounted respectively in the frame member I2 and the support 36. Said pawl is normally held out of engagement with the teeth of the gear segment I28 by a spring I 32 having one end thereof secured to the pin I3I and the other end in operative engagement with a peg I33. An upwardly extending handle I34 is provided on the pawl for moving said pawl into engagement with the gear segment. A peg I34a, set in the frame member I 2, limits the outward movement of the pawl.

In locking the valve mechanism with the pawl the valve is not fully opened so that the motor can operate said mechanism a little farther upon the resumption of the electric current supply to the motor. A slight operation of the mechanism by the motor will release the pawl. Consequently, with the thermostat calling for heat, the reestablishment of the electric current to the motor will cause said motor to operate the valve mechanism to the fully open position thereby moving the arm I28 and disengaging the pawl I20 from the gear segment.

Holes I35 in the arm are provided for securing damper or draft chains thereto for operating dampers or draft doors on the furnace. As the arm 52% moves with the actuating of the valve said dampers or draft doors may be opened and closed as the valve is opened and closed. Damper or draft chains may be attached to either side of the arm for operating doors hinged either at the top or the bottom.

A cover 536 encloses the mechanism above the base I0 and is secured thereto by a nut I31 on a bolt I38 secured at the lower end to the frame member I I. The cover is provided with a door I39 to provide ready access to the relays without removing the entire cover, said door having lugs I40 along the upper edge thereof adapted to hook under the cover and a screw I4I, screwed into a stud I42 of the base I0, secures the door thereto. An auxiliary door I43 provides ready access to electric posts therebehind and is secured to the cover by a screw I45. An insulated opening I46 provides an entrance for electric Wires connected to the electric circuits of the valve operating mechanism.

An opening I4! in the face of the cover exposes portions of the dial 14. The words off and on on the dial are exposed through the openings I41 when the valve is in the off and on positions respectively. When the valve is in the modulating position the numbers 4, 3, 2, l on the dial are exposed through the opening and the indicating arrow 8'! points to the respective valve adjustment position. Valve adjustment positions are also marked on the cover. Modulating adjustments of the valve can only be made when the valve is in the open or in the closed position.

As the electric motor operates on low voltage a suitable transformer I48 is provided.

In the electric circuits shown in Figure 8 a metal strap M9 is provided to form a contact between contact post I50 and contact post ISI for maintaining an unbroken circuit therebetween. Should a pilot light be used in the furnace the strap I49 is removed from the posts I50 and HI and the wires I52 and I53 connected to the thermostat of the pilot light.

Having thus described my invention what I claim is:

1. Fluid fuel control means comprising a valve, means for opening the valve, said means having an arm operatively associated therewith adapted to move with the operative movements of the valve, a pawl, means for moving the pawl into engagement with the arm to limit the movement of the arm in one direction at a position intermediate of the extreme limits of movement of said arm, means for releasing the pawl from engagement with the arm, and means for yieldingly maintaining the pawl in the arm engaging position.

2. Fluid fuel control means comprising a valve, electric-motor-driven means for opening the valve, means for closing the valve, a pawl for re leasably interrupting the return movement of the valve for limiting the flow of gas through said valve a relay for bringing the pawl into the interrupting position an electric control circuit for said relay 2. second relay for controlling the circuit of the first mentioned relay a control circuit for said second relay and thermostatic means for controlling the motor and relay circuits.

3. Fluid fuel control means comprising a valve, means for opening the valve, means for closing the valve, means for interrupting the closing of the valve at a predetermined position, an electric fan switch, and means for closing said switch when the valve is in the interrupted position, said switch automatically opening upon the valve leaving said interrupted position.

4. Fluid fuel control means comprising a valve, means for opening the valve, means for returning the valve to the closed position, means for interrupting the closing of the valve at a predetermined position to permit a limited flow of fuel through the valve, an indicator dial fixed to a shaft of the valve mechanism and adapted to rotate therewith, and means for adjusting the interruptecl position of the valve to regulate the amount of gas passing through the valve in said interrupted position and indicating said adjusted positions on the indicator dial.

JAMES WHALEN. 

